CN105404238A - Probe position linearization calibration method for on-machine laser measurement - Google Patents
Probe position linearization calibration method for on-machine laser measurement Download PDFInfo
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- CN105404238A CN105404238A CN201510691451.9A CN201510691451A CN105404238A CN 105404238 A CN105404238 A CN 105404238A CN 201510691451 A CN201510691451 A CN 201510691451A CN 105404238 A CN105404238 A CN 105404238A
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/18—Numerical control [NC], i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of programme data in numerical form
- G05B19/401—Numerical control [NC], i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of programme data in numerical form characterised by control arrangements for measuring, e.g. calibration and initialisation, measuring workpiece for machining purposes
- G05B19/4015—Numerical control [NC], i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of programme data in numerical form characterised by control arrangements for measuring, e.g. calibration and initialisation, measuring workpiece for machining purposes going to a reference at the beginning of machine cycle, e.g. for calibration
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B2219/00—Program-control systems
- G05B2219/30—Nc systems
- G05B2219/37—Measurements
- G05B2219/37008—Calibration of measuring system, probe, sensor
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- Length Measuring Devices By Optical Means (AREA)
Abstract
The invention discloses a probe position linearization calibration method for on-machine laser measurement. The method comprises steps that, a measurement model of a laser probe moving along with a machine tool is established, a machine tool motion program is generated in an offline mode, the laser probe is driven by the machine tool to carry out multi-angle scanning of a standard ball for ball center fitting, a linear equation group of a standard ball center under multiple machine tool rotation angles and a probe mounting position relationship is acquired, probe mounting position parameters can be acquired through solving the equation group, that a calibration problem is expressed as a nonlinear optimization problem with constraint is not required, and problems of massive calculation and instability existing in nonlinear optimization solution can be avoided.
Description
Technical field
The invention belongs in machine laser measuring technique field, more specifically, relate to a kind of method that gauge head at machine laser measurement installs pose demarcation and error compensation.
Background technology
Take laser measurement as the contactless measurement of representative, have speed fast, without wearing and tearing, do not need to carry out the advantages such as Probe-radius Compensation in Reserve, under the prerequisite meeting measuring accuracy, can significantly improve the efficiency of measurement, and more detailed surface information can be obtained.On-machine measurement can problem in Timeliness coverage manufacturing engineering, and then can introduce the measures such as error compensation and revise these problems in time.A kind of important form of on-machine measurement is by the main shaft end of one dimension distance measuring type laser feeler clamping at numerically-controlled machine, the laser line scanning measured workpiece surface driving laser feeler to send by machine tool motion, the distance measure obtained in conjunction with laser feeler and the beginning parameter transform model of each axle of lathe go out the three-dimensional coordinate of each sampling instant laser rays and surface of the work intersection point.
Laser feeler is arranged on the motive spindle of lathe by mechanical clamping mechanism, but the installation pose of laser feeler is difficult to accurate adjustment.In order to compensate the measuring error that installation site and drift angle cause, classic method utilizes Position-Sensitive Detector and specially designed clamp mechanism, manually laser feeler beam axis is adjusted, make it by the centre of gyration of gauge head solid of revolution, but the operation of manual adjustments beam direction is very inconvenient, and precision is larger by human factor.Occurred afterwards using V-block to realize the demarcation of laser feeler beam direction, but the method can only solve gauge head Installation posture, can not determine installation site.In order to obtain laser feeler light beam null position, occurring that use standard ball carries out the demarcation of gauge head installation site, having realized the demarcation of laser feeler beam direction in conjunction with V-block, but because two will be used in whole demarcation demarcate thing, made calibration process more loaded down with trivial details.In order to improve calibration technique further, there is the method simultaneously calibrating laser feeler beam direction and light beam null position with single standard ball, Installation posture is asked for by the position relationship setting up gauge head and standard ball under multiple directions, but problem of calibrating is expressed as the nonlinear optimal problem of belt restraining, the unconstrained optimization objective function of parameter to be calibrated is set up by penalty function, and then adopt genetic algorithm carry out non-linear search optimizing, unavoidably occurred nonlinear optimization solve in a large amount of calculating and instability problem.
Summary of the invention
For above defect or the Improvement requirement of prior art, the invention provides a kind of linearization scaling method of gauge head installation pose in machine laser scanning measurement, utilize standard ball realize gauge head install after the linearization technique demarcated of beam direction and light beam null position, efficiently avoid nonlinear optimization solve in a large amount of calculating and instability problem.
The invention provides a kind of linearization scaling method of gauge head pose in machine laser measurement, the method comprises the following steps:
A linearization scaling method for gauge head pose in machine laser measurement, is characterized in that, comprise the following steps:
Step one, default gauge head scanning pattern;
Step 2, generation lathe NC driving instruction: rotate rotary axis of machine tool, under making laser feeler remain on certain attitude, calculate measuring route position according to position relationship between the gauge head scanning pattern preset and the standard ball centre of sphere again, and generate the NC driving instruction driving lathe;
Step 3, data acquisition: lathe drives gauge head to scan along presetting scanning pattern standard ball, and gathering laser feeler measured value is d
itime corresponding machine tool chief axis translate coordinate system under k lathe reading
wherein, described gauge head measured value d
ifor certain any distance value on gauge head to standard ball sphere, and can be any given, but need to ensure d
imeasure in field depth at gauge head;
Step 4, least square fitting centre of sphere S
1: for lathe reading under the main shaft translate coordinate system that step 3 gathers
with the gauge head measured value d that least-squares algorithm matching is corresponding
icentre of sphere S
1;
Step 5, be based upon the mathematical model of machine laser measurement: according to the difference of used machine tool structure, measuring mathematical model can difference to some extent, but principle is similar, is all to carry out measurement space a bit by the rotation and translation motion of lathe.General mathematics model is:
Wherein, P is lathe spatially any point coordinate, R
aCfor lathe rotation matrix,
for the beam direction of gauge head,
for the optics setting-up eccentricity at zero point of gauge head, Q is lathe translation motion reading.Therefore, standard ball centre of sphere S
0with the lathe reading centre of sphere S of matching in step 4
1meet this mathematical model.Be organized into linear equation form:
Wherein, I is the unit matrix of 3 × 3.
The calibration result of step 6, acquisition gauge head pose: by repeatedly changing the attitude of gauge head on lathe, repeats step 2 to step 4, in order by the centre of sphere S of repeatedly matching
1bring linear equation into respectively, set up system of linear equations, to obtain S
0,
optimum solution.
Further, it is characterized in that, before being also included in described step one, spray developer to described standard ball.
Further, gauge head scanning pattern in described step one is: from LASER SPECKLE just to the standard ball centre of sphere, mobile gauge head carries out the rectilinear motion come and gone to 8 directions, 8 directions are in same plane, and adjacent both direction angle is 45 degree, scanning pattern is symmetrical " rice " font, after 8 scanning directions are complete, make gauge head gradually away from standard ball, every 2mm multiple scanning one time.
Further, in described step 4, least-square fitting approach is: during each least square fitting centre of sphere, obtain average error and the standard deviation of matching, by average error and three times of standard deviations and be set to threshold value, reject the coordinate points that error is greater than threshold value, matching centre of sphere calculated threshold again, till institute is somewhat qualified.
Further, described developer thickness is less than gauge head measuring error.
The method using gauge head calibration value to compensate gauge head pose, is characterized in that, the standard ball centre of sphere solved respectively under different corner solves the difference of value and calibration value, offset when this difference being measured as all directions.
The present invention compared with prior art, can obtain following beneficial effect:
1. problem of calibrating is expressed as the linear optimization problem solving the standard ball centre of sphere and machine tool position relation, carry out the multi-angle matching machine tool motion position centre of sphere can solve simultaneously laser feeler install Position and orientation parameters, efficiently avoid nonlinear optimization solve in a large amount of calculating and instability problem.
2. by off-line generation machine bed motion program, make lathe automatic traction gauge head carry out multi-angle scanning survey to standard ball, calibration process is simple, is easy to operation.
Accompanying drawing explanation
Fig. 1 is the linearization scaling method process flow diagram of a kind of gauge head pose in machine laser measurement of the present invention;
Fig. 2 is at machine laser measurement motion schematic diagram in embodiment;
In all of the figs, identical Reference numeral is used for representing identical element or structure, wherein: 1-worktable, 2-standard ball, 3-laser feeler, 4-numerically-controlled machine, 5-rotary main shaft.
Embodiment
In order to make object of the present invention, technical scheme and advantage clearly understand, below in conjunction with drawings and Examples, the present invention is further elaborated.Should be appreciated that the demarcation embodiment in Double swing head five-axle number control machine tool described herein is only in order to explain the present invention, is not intended to limit the present invention.In addition, if below in described each embodiment of the present invention involved technical characteristic do not form conflict each other and just can mutually combine.
Basic thought of the present invention is: according to laser feeler on-machine measurement mathematical model, and between multiple corner Criterion ball centre of sphere and the machine coordinates matching centre of sphere, the linear equation of position relationship, realizes the demarcation to laser feeler Installation posture.
Below in conjunction with concrete enforcement and accompanying drawing, the present invention is described in further detail.
As shown in Figure 2, a kind of Double swing head lathe, worktable is static relative to lathe.By the clamping mechanism of design, one dimension distance measuring type laser feeler is arranged on main shaft, and main shaft is locked.In the ideal case, optical measuring head beam direction is consistent with machine Z-axis axis direction, and the optics null position of gauge head is on Z axis axis.But because gauge head does not have accurate positioning datum when mounted, bias and inclination angle will inevitably be produced.These alignment errors will reduce measuring accuracy, therefore need a kind of gauge head pose scaling method reliably.
First each coordinate system in the gauge head measurement model shown in Fig. 2 is set up.
1) lathe world coordinate system Cmw: the intersection point of turning axle A, C axis when the initial point of coordinate system is lathe back to zero.X, Y, Z tri-three motion guide rail directions in direction and lathe of axle are consistent.Lathe world coordinate system by the impact of machine tool motion, is not a fixed coordinate system.
2) machine tool chief axis translate coordinate system Ct: the initial point of this coordinate system is the intersection point of turning axle A, C axis, and move together along with main shaft, three change in coordinate axis direction are consistent with lathe world coordinate system three direction of principal axis.When zero point got back to by lathe, machine tool chief axis translate coordinate system overlaps with lathe world coordinate system.
3) machine tool chief axis rotating coordinate system Cr: when rotating lathe A, C axle, coordinate system Cr rotates with A, C axle.When the corner of rotary axis of machine tool A, C is 0 °, coordinate system Cr overlaps with coordinate system Ct.
According to machine tool motion, machine tool chief axis translate coordinate system Ct and lathe world coordinate system C
mwbetween only have translation relation, characterize the translation motion of lathe, can be expressed as
wherein, Q is machine coordinates reading, directly can read from lathe.When machine tool chief axis rotates to arbitrarily angled, machine tool chief axis rotating coordinate system C
rwith machine tool chief axis translate coordinate system C
tonly have rotation relationship, note turning axle A, C corner is respectively θ
aand θ
c(θ
a, θ
cdirection meets right-handed coordinate system), then rotation matrix is:
In formula:
Wherein R
a, R
cby rotary axis of machine tool A, C rotational angle theta
aand θ
ccalculate.
As shown in Figure 3, gauge head material object is substituted with simple straight-line segment.The setting-up eccentricity of optics P at the zero point point of gauge head
line segment MN, NP, O is used respectively at the axial translational movement of X, Y, Z tri-
rm represents, and three line segments are vertical between two.
When gauge head clamping is on main shaft, optics P at the zero point point of laser feeler is at machine tool chief axis rotating coordinate system C
runder there is setting-up eccentricity, be expressed as
the beam direction mounting shift angle of laser feeler is expressed as
after gauge head is clamping, these parameters are definite value, meet following equation:
D is laser feeler measured value, and these parameters can obtain in real time in on-machine measurement process.(1) formula is brought in (2) formula and obtains:
Wherein:
for standard ball centre of sphere S
0coordinate figure,
for the centre of sphere S of matching
1coordinate figure.
Therefore by keeping lathe rotational angle theta
a, θ
cand gauge head measured value d is constant, standard ball sphere is measured abundant point, by the lathe reading matching centre of sphere of correspondence, just can obtain one group of linear equation.Have 3 equations, 9 unknown quantitys in formula (3), change lathe rotational angle theta
a, θ
cand gauge head measured value d measures 3 groups of data, can set up the system of linear equations containing 9 linear equations, thus solve parameter to be calibrated.Increase pendulous frequency and set up over-determined systems, solving equation least square solution, contribute to the impact reducing stochastic error, improve stated accuracy.
A linearization scaling method for gauge head pose in machine laser measurement, as shown in Figure 1, comprises the following steps:
Step one: to standard ball spraying developer: standard ball selects diameter to be the high-precision ceramic balls of 20mm, improves laser sensor measuring accuracy at standard ball surface spraying developer.Developer spraying is even and thickness is less than gauge head measuring accuracy.
Step 2: planning gauge head scanning pattern: the good measuring route of advance planning, makes gauge head according to the route scanning of design, records the data that standard ball surface is abundant.Scanning pattern is from LASER SPECKLE just to the standard ball centre of sphere, and mobile gauge head carries out rectilinear motion to 8 directions and turns back to start position, becomes symmetrical " rice " font.8 directions are in same plane, and adjacent both direction angle is 45 degree.After a flat scanning is complete, make gauge head gradually away from standard ball, every 2mm multiple scanning one time.
Step 3: standard ball position centering: use handwheel to forward lathe A, C axle to setting value, then mobile machine tool makes laser facula be irradiated to directly over standard ball, roughly estimate standard ball sphere center position, and calculate measuring route position with this rough centre of sphere, final generation lathe NC program.
Step 4: data acquisition:
Lathe runs the NC program of generation, lathe is made to drive laser feeler to scan along the path designed standard ball, and use gauge head Survey Software to read the distance measure of gauge head, when gauge head measured value is 90mm, 100mm (can not exceed gauge head field depth), preserve machine coordinate values now respectively
Step 5: the least square fitting centre of sphere.
For the two groups of machine coordinates points preserved
centre of sphere when being 90mm, 100mm with least-squares algorithm matching corresponding to gauge head measured value respectively.During each least square fitting centre of sphere, obtain average error and the standard deviation of matching, by average error and three times of standard deviations and be set to threshold value, reject the coordinate points that error is greater than threshold value.Matching centre of sphere calculated threshold again, till institute is somewhat qualified.The centre of sphere of matching is brought respectively into linear equation below:
Wherein: I is 3x3 unit matrix, R
a, R
cfor rotation matrix, calculated by rotary axis of machine tool A, C corner, d is laser feeler measured value, S
1for the centre of sphere of least square fitting, these parameters can obtain in on-machine measurement process.S
0for the centre of sphere of standard ball,
for the beam direction of laser feeler,
for the optics setting-up eccentricity at zero point of laser feeler.
Step 6: change corner, duplicate measurements: change lathe A, C Shaft angle and repeat step 3, step 4, step 5, set up A, C Shaft angle respectively and be (60 °, 45 °), (60 °,-45 °), (-60 °, 45 °) and (-60 ° ,-45 °) time equation, and solving equation group is to obtain S
0,
optimum solution.
Further, all angles that machine tool chief axis can rotate to are separated into k group angle, are designated as by a kind of gauge head posture compensation method at machine laser measurement
only need during measurement to measure under these limited lathe pivot angles, just effectively can make compensation to the measurement result under these angles.
According to calibration principle, need to rotate machine tool chief axis in multiangular measurement standard ball to set up system of equations.The present invention using discrete go out k group angle as demarcate in use taking measurement of an angle, if the calibration result of the standard ball centre of sphere, beam direction and light beam bias at zero point is respectively:
The beam direction calibrated and light beam bias at zero point are brought in formula (2), tries to achieve respectively and at corner be
time the standard ball centre of sphere, be designated as
known with corner
error during measurement is:
In formula:
be respectively with corner
the centre of sphere of lathe reading matching during measurement and the rotation matrix of A, C axle.In like manner can in the hope of the measuring error of other angles, this error is offset during measurement.
The present invention relates to a kind of linearization technique being used in machine laser measurement gauge head installation pose and demarcating, belong in machine laser measuring technique field.The technical scheme adopted is: set up the measurement model of laser feeler with machine tool motion, by off-line generation machine bed motion program, make lathe drive gauge head to carry out multi-angle scanning to standard ball and carry out the matching centre of sphere, obtain the standard ball centre of sphere installs position orientation relation under multiple lathe corner system of linear equations with gauge head.Solving equation group can obtain gauge head and install pose parameter, and does not need nonlinear optimal problem problem of calibrating being expressed as belt restraining, avoid nonlinear optimization solve in a large amount of calculating and instability problem.For the kinematic error of each axle of lathe in measuring on the impact of measurement result, provide the effective ways compensating machine tool system error.This method not only effectively realizes demarcating gauge head pose, and calibration process is simple, is easy to operation.
Those skilled in the art will readily understand; the foregoing is only preferred embodiment of the present invention; not in order to limit the present invention, all any amendments done within the spirit and principles in the present invention, equivalent replacement and improvement etc., all should be included within protection scope of the present invention.
Claims (6)
1. the linearization scaling method of gauge head pose in machine laser measurement, is characterized in that, comprise the following steps:
Step one, default gauge head scanning pattern;
Step 2, generation lathe NC driving instruction: rotate rotary axis of machine tool, under making laser feeler remain on certain attitude, calculate measuring route position according to position relationship between the gauge head scanning pattern preset and the standard ball centre of sphere again, and generate the NC driving instruction driving lathe;
Step 3, data acquisition: lathe drives gauge head to scan along presetting scanning pattern standard ball, and gathering laser feeler measured value is d
itime corresponding machine tool chief axis translate coordinate system under k lathe reading
wherein, described gauge head measured value d
ifor certain any distance value on gauge head to standard ball sphere, and can be any given, but need to ensure d
imeasure in field depth at gauge head;
Step 4, least square fitting centre of sphere S
1: for lathe reading under the main shaft translate coordinate system that step 3 gathers
gauge head measured value d is corresponded to least-squares algorithm matching
icentre of sphere S
1;
Step 5, be based upon the mathematical model of machine laser measurement: according to the difference of used machine tool structure, measuring mathematical model can difference to some extent, but principle is similar, is all to carry out measurement space a bit by the rotation and translation motion of lathe.General mathematical model is:
Wherein, P is lathe spatially any point coordinate, R
aCfor lathe rotation matrix,
for the beam direction of gauge head,
for the optics setting-up eccentricity at zero point of gauge head, Q is lathe translation motion reading.Therefore, standard ball centre of sphere S
0with the lathe reading centre of sphere S of matching in step 4
1meet this mathematical model.Be organized into linear equation form:
Wherein, I is the unit matrix of 3 × 3.
The calibration result of step 6, acquisition gauge head pose: by repeatedly changing the attitude of gauge head on lathe, repeats step 2 to step 4, in order by the centre of sphere S of repeatedly matching
1bring linear equation into respectively, set up system of linear equations, obtain S
0,
optimum solution.
2. the linearization scaling method of a kind of gauge head pose in machine laser measurement as claimed in claim 1 or 2, is characterized in that, is also included in before described step one to described standard ball spraying developer.
3. the linearization scaling method of a kind of gauge head pose in machine laser measurement as claimed in claim 1, it is characterized in that, gauge head scanning pattern in described step one is: from LASER SPECKLE just to the standard ball centre of sphere, mobile gauge head carries out the rectilinear motion come and gone to 8 directions, 8 directions are in same plane, and adjacent both direction angle is 45 degree, scanning pattern is symmetrical " rice " font, after 8 scanning directions are complete, make gauge head gradually away from standard ball, every 2mm multiple scanning one time.
4. the linearization scaling method of a kind of gauge head pose in machine laser measurement as claimed in claim 1 or 2, it is characterized in that, in described step 4, least-square fitting approach is: during each least square fitting centre of sphere, obtain average error and the standard deviation of matching, by average error and three times of standard deviations and be set to threshold value, reject the coordinate points that error is greater than threshold value, matching centre of sphere calculated threshold again, till institute is somewhat qualified.
5. the linearization scaling method of a kind of gauge head pose in machine laser measurement as claimed in claim 1 or 2, it is characterized in that, described developer thickness is less than gauge head measuring error.
6. the method using the gauge head calibration value obtained as claim 1-5 any one to compensate gauge head pose, it is characterized in that, the standard ball centre of sphere solved respectively under different corner solves the difference of value and calibration value, offset when this difference being measured as all directions.
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